Shipping container with compostable insulation

ABSTRACT

In one aspect, a shipping container includes a plurality of thermally insulating pads positioned in a cavity in a box. Each pad of the plurality of thermally insulating pads includes a solid compostable panel formed primarily of extruded milled sorghum, the panel providing a rectangular plate, and a compostable water-proof film forming a pocket enclosing the panel. The panel is loose within the pocket. At least one of the plurality of thermally insulating pads includes a multi-section panel including a score across its width in at least one location. The score extends partially but not entirely through the thickness of the multi-section panel. The multi-section panel is folded at a right angle at the score such that the panel provides a plurality of rectangular plates dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the plurality of plates is adjacent.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/094,787, filed Apr. 8, 2016, which is a continuation-in-part of U.S.application Ser. No. 15/089,344, filed on Apr. 1, 2016, each of which isincorporated by reference in its entirety.

TECHNICAL FIELD

This invention relates to an insulated shipping container, and moreparticularly to a shipping container in which the insulation iscompostable.

BACKGROUND

A conventional container for shipping temperature sensitive productsincludes a cardboard box, inside of which is a thermally insulatingmaterial. A conventional thermally insulating material is expandedpolystyrene (EPS), e.g., Styrofoam. For example, panels of the expandedpolystyrene can line the walls of the box, and another packing material,e.g., bubble wrap, can be placed surround and cushion the item beingshipped inside the panels. Alternatively, expanded polystyrene can bemachined or molded to form a “cooler” into which the item being shippedcan be placed—this does not need an external box. In either case, acoolant, e.g., ice, dry ice or a gel pack, is placed in the cavity inthe box with the item being shipped.

EPS is relatively inexpensive and easily formed into a variety ofshapes, but is not compostable. Consequently, disposing of the materialof the container can be a problem.

SUMMARY

A container is described that provides for thermal insulation of an itembeing shipped while the components are still recyclable or compostable.

In one aspect, a shipping container to hold an item includes an exteriorbox, a cover to close off a top of the box, and a plurality of thermallyinsulating pads positioned in a cavity in the box. The box has a floorand a plurality of side walls to define the cavity therein and anopening to the cavity at the top of the box. The plurality of thermallyinsulating pads are positioned such that each of the floor, plurality ofside walls and cover are adjacent to and covered by a pad from theplurality of thermally insulating pads. The plurality of thermallyinsulating pads are shaped to provide an interior space to receive theitem. Each pad of the plurality of thermally insulating pads includes asolid compostable panel formed primarily of extruded milled sorghum, thepanel providing a rectangular plate dimensioned to substantially spanwhichever of the floor, plurality of side walls or cover that therectangular plate is adjacent, and a compostable water-proof filmforming a pocket enclosing the panel. The panel is loose within thepocket. At least one of the plurality of thermally insulating padsincludes a multi-section panel including a score across its width in atleast one location. The score extends partially but not entirely throughthe thickness of the multi-section panel. The multi-section panel isfolded at a right angle at the score such that the panel provides aplurality of rectangular plates dimensioned to substantially spanwhichever of the floor, plurality of side walls or cover that theplurality of plates is adjacent.

In another aspect, a shipping container to hold an item includes anexterior box, a cover to close off a top of the box, and a thermallyinsulating pad positioned in a cavity in the box. The exterior box has afloor and a plurality of side walls to define the cavity therein and anopening to the cavity at the top of the box. The insulating pad ispositioned such that each of the floor, plurality of side walls andcover are adjacent to and covered by a portion of the pad. The thermallyinsulating pad is shaped to provide an interior space to receive theitem. The thermally insulating pad includes a solid compostable panelformed primarily of extruded milled sorghum, and a compostablewater-proof film forming a pocket enclosing the panel. The panel isloose within the pocket. The multi-section panel is scored across itswidth in at least five locations, each score extending partially but notentirely through the thickness of the multi-section panel. Themulti-section panel is folded at a right angle at each score such thatthe panel provides six rectangular plates, each plate of the sixrectangular plates dimensioned to substantially span whichever of thefloor, plurality of side walls or cover that the plate is adjacent.

In another aspect, a shipping container to hold an item includes anexterior box, a cover to close off a top of the box, and six thermallyinsulating pads positioned in a cavity in the box. The exterior box hasa floor and a plurality of side walls to define the cavity therein andan opening to the cavity at the top of the box. The six thermallyinsulating pads are positioned such that each of the floor, plurality ofside walls and cover are adjacent to and covered by a pad from theplurality of thermally insulating pads. The six thermally insulatingpads are shaped to provide an interior space to receive the item. Eachpad of the six thermally insulating pads includes a solid compostablepanel formed primarily of extruded milled sorghum, the panel providing arectangular plate dimensioned to substantially span whichever of thefloor, plurality of side walls or cover that the rectangular plate isadjacent, and a compostable water-proof film forming a pocket enclosingthe panel. The panel is loose within the pocket.

Implementations may optionally include one or more of the followingfeatures.

The panel of each pad may have a uniform homogenous composition. Thepanel of each pad may be a unitary body. The panel of each pad may havea thickness between of about ¼ and 1 inch. The panel of each pad mayhave a density of about 0.5 to 3.5 g/cm³. Surfaces of the panel of eachpad may be basically flat, or one or more surfaces of the panel of eachpad are corrugated.

One or more apertures may be formed through the water-proof film on aside of the pad closer to the exterior box. The compostable water-prooffilm may completely cover the panel on the side of the pad farther fromthe exterior box. The one or more apertures may be about ⅛ to 5 inchesacross. The score may form a recess extending through about 50-75% of athickness of the multi-section panel. At least pad may include aplurality of stacked panels.

The exterior box may be a cardboard box. The cover may include one ormore flaps extending from one or more side walls of the container.

In one aspect, a shipping container to hold an item includes an exteriorbox, a cover to close off a top of the box, and a plurality of thermallyinsulating panels positioned in a cavity in the box. The box has a floorand a plurality of side walls to define the cavity therein and anopening to the cavity at the top of the box. The plurality of thermallyinsulating panels are positioned such that each of the floor, pluralityof side walls and cover are adjacent to and covered by a panel from theplurality of thermally insulating panels. The plurality of thermallyinsulating panels are shaped to provide an interior space to receive theitem. Each panel of the plurality of thermally insulating panelsconsists of a solid compostable panel formed primarily of extrudedmilled sorghum, the panel providing a rectangular plate dimensioned tosubstantially span whichever of the floor, plurality of side walls orcover that the rectangular plate is adjacent. At least one of theplurality of thermally insulating panels includes a multi-section panelincluding a score across its width in at least one location. The scoreextends partially but not entirely through the thickness of themulti-section panel. The multi-section panel is folded at a right angleat the score such that the panel provides a plurality of rectangularplates dimensioned to substantially span whichever of the floor,plurality of side walls or cover that the plurality of plates isadjacent.

In another aspect, a method of fabricating a shipping container to holdan item includes fabricating a plurality of thermally insulating pads,each pad fabricated by placing a solid compostable panel formedprimarily of milled sorghum between two sheets of compostablewater-proof film, and heat sealing the two sheets such that the panel isenclosed in a pocket of water-proof film that completely surrounds thepanel with the panel loose in the pocket. At least one of the pluralityof thermally insulating panels is scored across its width to provide amulti-section panel. The multi-section panel is folded at a right angleat the score such that the panel provides a plurality of rectangularplates. The plurality of thermally insulating pads are inserted into acavity of an exterior box such that each of a floor, plurality of sidewalls and cover of the box is adjacent to and covered by a pad from theplurality of thermally insulating pads and the plurality of thermallyinsulating pads provide an interior space to receive the item. Eachrectangular plate is dimensioned to substantially span whichever of thefloor, plurality of side walls or cover that the rectangular plate isadjacent.

Potential advantages may include (and are not limited to) one or more ofthe following.

The insulating material is compostable, and the exterior box isrecyclable, so all of the components of the container are easilydisposable. The container can be easily assembled, and the insulatingpads that fit inside the container can be manufactured at low cost. Theinsulating pads can provide equivalent thermal insulation to expandedpolystyrene, and can be disposed in commercial and residential recyclingbins or garbage cans. The container components can be shipped in bulk inan unassembled state with minimal cost increase, and assembly of thecontainer can be performed by the user.

The details of one or more embodiments are set forth in the accompanyingdrawings and the description below. Other features, objects, andadvantages of the invention will be apparent from the description anddrawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is an exploded perspective view of an example of an insulatedshipping container.

FIGS. 2A-2G illustrate an example of construction of the pads of theinsulating shipping container of FIG. 1.

FIGS. 3A-3I illustrate an example that includes two three-sectioned padsfor the insulating shipping container.

FIGS. 4A-4D illustrate an example that includes six individual pads forthe insulating shipping container.

FIGS. 5A-5H illustrate an example that includes a three-sectioned padand three individual pads for the insulating shipping container.

FIG. 6 illustrates an example that includes a single six-sectioned pad.

FIGS. 7A and 7B illustrates an example of multiple multi-section panelsenclosed in a water-proof film, in an unfolded and folded state,respectively.

FIG. 8 illustrates an example of using solid compostable panels, withouta water-proof film, for an insulated shipping container.

FIG. 9 illustrates multiple panels that are laminated together.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

Most conventional thermally insulating materials for packaging, e.g.,EPS, are not compostable. One technique for using a compostableinsulating packaging material is to fill a volume between an inner walland an outer wall of a box with loose-fill compostable cornstarch foampellets (e.g., packing “peanuts”) using layered stratification, and thencompress each layer of foam pellets in within this volume to compactthem. This technique requires either multiple boxes or a specialized boxhaving both inner and outer walls, and also requires specializedmachinery for layered stratification compaction of the pellets. Theadditional or specialized boxes increase the cost. In addition, theloose fill pellets are difficult to compost because they are messy whenremoved from the box. Moreover, a large amount of pressure, e.g., 25lbs. or more, needs to be applied to close the top flaps of the box dueto the resistance from the pellets.

However, instead of loose-fill foam pellets, a solid compostable panelformed primarily of milled extruded sorghum can be enclosed by acompostable water-proof film to provide a thermally insulatingcompostable pad, and this pad can be used as the insulating packagingmaterial in the container.

FIG. 1 is an exploded perspective view of an example of an insulatedshipping container 10. The shipping container 10 includes a box 20 andmultiple thermally insulating pads 30 that fit inside an interior cavity22 of the box 20. The thermally insulating pads 30 are shaped such thatwhen positioned in the box 20 they provide an interior space to receivethe item and optionally a coolant, e.g., ice, dry ice or a gel pack.

The box 20 can be a rectangular prism, and can includes rectangular sidewalls 24 that define the interior cavity 22. The bottom of the box maysimilarly be closed off by one or more flaps (not shown due to theperspective view). The top of the box 20 provides an opening to theinterior cavity 22. A cover for the box 20 can be provided by one ormore flaps 26 that can be folded inwardly from the side walls 24 toclose off the top of the cavity 22. In some implementations, the sidewalls 24, flaps 26 and bottom of the box are all part of a singleintegral sheet that is folded into an appropriate shape. Alternatively,the cover for the box 20 can be provided by a separate lid that fitsover the side walls 24.

The box 20 is a recyclable material. For example, the box 20 can be acardboard box, e.g., paper board or corrugated cardboard.

As noted above, the container includes multiple thermally insulatingpads 30 that fit inside the box 20. Each pad 30 is formed by sealing asolid compostable panel (or multiple solid compostable panels) within acompostable water-proof film. Each pad 30 is relatively thin, e.g.,about 0.25-4 inch thick, as compared to the length and width of the pad.The thickness of a pad 30 is considered to be along its narrowestdimension, whereas the length and width of the pad 30 are considered tobe along the two directions along the primary face, perpendicular to thethickness.

Each panel can be formed primarily of extruded milled sorghum (sorghumis also known as milo). Other materials that do not interfere with thecompostable nature of the panel, e.g., a softener to improve adhesion ofthe milled sorghum, a preservative or anti-fungal agent, can be present,but only in small quantities. For example, at least 85%, e.g., at least90-95%, by weight of the panel is sorghum. Polyvinyl alcohol can bepresent, e.g., 5-10% by weight.

Each panel is “solid”, which in this context indicates that the panelholds together as a single unit, rather than being formed of loose-fillpellets. It may be noted that compressed starch pellets would not form asolid part; upon removal of pressure the pellets would disassemble, andincreased pressure only fractures or pulverizes the pellets. A solidpanel of extruded milled sorghum provides significant thermalinsulation, while still being compostable.

It is possible for the panels to be a foam material, e.g., to includesmall pores or voids spread substantially uniformly through the panel.For example, 10-80% of the volume of the panel can be pores or voids,e.g., 25-75%, 25-50%, 10-25%, 50-75%. The maximum size of the pores orvoids can be about 1 mm. Although the panel could be a foam material, itis generally incompressible. The density of a panel can be about 0.4-3.5g/cm³, e.g., 0.6-1.0 g/cm³, 0.8-2.0 g/cm³, 1.0-3.5 g/cm³.

Each panel can be of a uniform homogenous composition. Furthermore, eachpanel can be a unitary body—that is the body of the panel holds togetherby itself without adhesives or fasteners to join multiple sectionstogether to form the panel.

The thickness of a panel can be about 0.25-1.0 inches, e.g., 0.25-0.75inches. Any given panel can have substantially uniform thickness acrossits primary surface. The surfaces of the panel can be generally flat, orone or more surfaces can be corrugated. Corrugation can increase theeffective thickness of the pad, e.g., by a factor of up to 4. In thiscase, the thickness of the panel can still be uniform, but the panel isshaped with corrugations.

Each panel can include one or more rectangular plates dimensioned tosubstantially span whichever of the floor, plurality of side walls orcover that the rectangular plate is adjacent. In some implementations,the whole of the panel, when in an unfolded configuration, is alsorectangular.

The panels can be formed by an extrusion process. After extrusion, eachpanel can be cut to the appropriate size. In addition, the edges canoptionally be beveled as to provide the beveling of the pads describedabove. In addition, the panel that provides the collar can be scored, asdescribed below.

The compostable water-proof film can be a plastic film, e.g., abioplastic, that meets ASTM D6400 standards. In some implementations,the film is air-tight. Suitable materials for the film include polymersbased on one or more of polylactic acid (PLA), poly(beta-amino) esters(PBAE), polyhydroxyalkanoate (PHA), polycapralactones (PCL),polybutyrate adipate terephthalate (PBAT) polyvinylalcohol (PVA), orethylene vinyl alcohol (EVOH). For example, a combination of PBAT and PEmay be suitable. As another example, a combination of PE and PLA may besuitable. In some implementations, the polymer can be mixed with anorganic product, e.g., a starch, such as corn starch.

A problem with starch-based insulation is that it dissolves easily inwater. If the item being shipped is cold or a coolant is placed in theinterior of the container 10, condensation can form on the interiorsurfaces of the pad 30. However, the film prevents liquid, e.g., thecondensation, from reaching the solid milled sorghum panel, thusenabling the milled sorghum panel to be usable as a thermal insulator inthe container.

To fabricate a pad 30, the solid milled sorghum panel can be placedbetween two sheets of the water-proof film. The edges of the water-prooffilm can be heat-sealed to each other, e.g., along the entire perimeterof the panel, thus enclosing and sealing the panel in a pocket of thecompostable water-proof film that has only slightly larger dimensionthan the panel itself. A suitable sealing temperature is above 100° C.Excess film outside the heat seal can be cut away.

Alternatively, the film can be provided in a tubular form. To fabricatea pad 30, the panel is slid inside the tube of water-proof film, and thetwo open ends of the tube are heat sealed. This forms a pocket in whichthe panel sits.

The panel sits loose inside the pocket formed by the film. That is, thepanel is not bonded or otherwise fixed to the film. Thus, the panel canslide inside the pocket relative to the film. For example, the film canbe in sliding contact with the panel. The interior of the pocket caninclude a small amount of air. In some implementations, the air isvacuumed out before the pocket is sealed. In the directions parallel tothe primary surface of the panels, the pocket can be up to about 0.5inches larger on each side than the panel.

Other than one or panels, there need not be any other thermallyinsulating material within the water-proof film. For example, unless oneof the panels fractures due to applied stress, there are no loosepellets or pieces of other insulating material in the volume enclosed bythe film. In some implementations, the pad 30 consists of, i.e.,includes only, one or more panels, the water-proof film, and some airinside the volume enclosed by the film.

In the implementation shown in FIG. 1, the thermally insulating pads 30include a bottom pad 32, a collar 34, and a top pad 36.

The bottom pad 32 has a length and width that match the bottom of thebox 20, or are slightly smaller, e.g., by about an ⅛ inch tolerance, sothat bottom pad 32 fits snugly at the bottom of the cavity 22 on thebottom of the box 20.

The collar 34 includes a single panel that is folded into four wallmembers 40. Each wall member 40 has a height (in the vertical direction)about equal to the height of the box 20, less the combined thickness ofthe top pad 32 and bottom pad 36. Each wall member 40 has a width (inthe lateral direction) that matches the adjacent side wall 24 of the box20, or is slightly smaller, e.g., e.g., by about an ⅛ inch tolerance.Thus, the collar 34 fits snugly into cavity 22 on top of the bottom pad32, with each wall member 40 adjacent, e.g., in contact with, one of theside walls 24.

The top pad 36 has a length and width that match the top of the box 20,or are slightly smaller, e.g., e.g., by about an ⅛ inch tolerance, sothat the perimeter of the top pad 36 can sits on the wall members 40 ofthe collar 34 and the top pad 36 itself fits snugly at the cavity 22.When the top of the box 20 is closed, e.g., by closing the flaps 26 orplacing a lid, the top pad 36 sits adjacent, e.g., in contact with, thetop of the box 20.

In some implementations, the surfaces of the pads 30 are basically flatup to and including their edges. “Basically flat” is used to indicateflat at the scale of the thickness of the pad, but still encompasses thepossibility of small scale surface texturing. Thus, the lower rim of thecollar 34 simply sits basically flat on the perimeter of the top surfaceof the bottom pad 32, and the perimeter of the top pad 36 simply sitsbasically flat on the upper rim of the collar 34. Alternatively, theinterior surfaces of each pad, i.e., the surface of the pad facing thecavity and further from the box 20, can be beveled at the edge that isadjacent another pad. Thus, the beveled lower rim of the collar 34 sitson the beveled perimeter of the bottom pad 32, and the beveled perimeterof the top pad 36 sits of the beveled upper rim of the collar 34. Inthis latter case, the outer surface of each wall member 40 can have aheight about equal to the height of the box 20.

FIGS. 2A-2G illustrate an example of construction of the pads 30 of theinsulating shipping container 10 shown in FIG. 1.

Referring to FIG. 2A, an exploded perspective view, the collar 34 can befabricated by forming a solid compostable panel 50 that has a length Lapproximately equal to or slightly less than the length of the lateralperimeter of the box 20, and a width W approximately equal or slightlyless than the height of the box 20. The panel 50 is then placed betweentwo sheets 60 of the compostable water-proof film. Referring to FIG. 2B,a cross-sectional side view, the two sheets 60 are heat sealed along apath than extends around the entire perimeter of the panel 50. The sealcan be positioned no more than about 1 inch, e.g., no more than about ½inch, from the edge of the panel 50. Excess film outside the heat sealcan be cut away.

FIG. 2C is a cross-sectional side view, and FIG. 2D is a perspectiveview. Referring to FIGS. 2C and 2D, before or after sealing the panel 50between the sheets 60, one surface of the panel 50 (which will be theinward facing surface of the panel) can be scored in three locations todivide the panel 50 into four rectangular plates 52, which correspond tothe four side walls of the collar 34. The length of each plate 52corresponds to the width of the corresponding side wall 50 of the collar34. Scoring can be performed by compression with an angled rigid body.

Each score can create a recess 56 that extends across the width W of thepanel. The recess 56 extends partially, but not entirely through thethickness of the panel 50. For example, the recess 56 can extend throughabout 50-75% of the thickness of the panel 50. The scoring can beangled, so the recess has a triangular cross-section.

The reduced thickness of the panel 50 in the scored areas increases theflexibility of the panel so that the panel 50 can be bent at a rightangle without breaking. In particular, the panel 50 can be foldedinwardly (with the inside surface being the side with the recess 56).This permits the panel 50 to remain as a single unitary part when thecollar 34 is folded and placed in the box 20, which can improve thermalinsulation by reducing creation of gaps in the insulating material.

FIG. 2E is a schematic exploded perspective view. FIG. 2F is a schematiccross-sectional side view. FIG. 2G is a schematic perspective view.Referring to FIGS. 2E-2G, construction of the top pad 32 and bottom pad36 is even simpler. A panel 50 is formed having lateral dimensionsapproximately equal to or slightly less than the correspondingdimensions of the top or bottom the box 20. This panel 50 is then placedbetween two sheets 60 of the compostable water-proof film (see FIG. 2E),and the two sheets 60 are heat sealed along a path than extends aroundthe entire perimeter of the panel 50 (see FIG. 2F) to provide the toppad 32 or bottom pad 36. Excess film outside the heat seal can be cutaway.

FIGS. 3A-3I illustrate another example of construction of the pads 30for the insulating shipping container 10. In the example of FIGS. 3A-3I,rather than three pads, the thermally insulating pads 30 include a firstthree-sectioned pad 70 and a second three-sectioned pad 72.

FIGS. 3A and 3B are schematic exploded perspective views of the twothree-sectioned pads. FIGS. 3C-3F are schematic cross-sectional sideview of the two three-sectioned pads. FIGS. 3G and 3H are schematicperspective views of the two three-sectioned pads. FIG. 3I is aschematic exploded perspective view showing how the two three-sectionedpads are positioned relative to each other.

These pads 30 are constructed similarly to the pads discussed above forFIGS. 2A-2D, with each pad 70, 72 formed by sealing a solid compostablepanel within a compostable water-proof film. In particular, eachthree-sectioned pad 70, 72 is constructed in a manner similar to thecollar 34 discussed above, but with scoring in two locations rather thanthree locations.

In particular, referring to FIG. 3A, the first three-sectioned pad 70can be fabricated by forming a solid compostable panel 50 that has alength L approximately equal to or slightly less than the length ofthree side walls of the box 20, and a width W approximately equal orslightly less than the height of the box 20. Referring to FIG. 3B, thesecond three-sectioned pad 70 can be fabricated by forming a solidcompostable panel 50 that has a length L approximately equal to orslightly less than the length of top and bottom of the box 20 plus theheight of one of the side walls of the box, and a width W approximatelyequal or slightly less than the lateral length of one of the side wallsof the box 20.

Referring to FIGS. 3A-3D, each panel 50 is then placed between twosheets 60 of the compostable water-proof film, and the two sheets 60 areheat sealed, as discussed above.

Referring to FIGS. 3E-3G, before or after sealing each panel 50 betweenthe sheets 60, one surface of the panel 50 (which will be the inwardfacing surface of the panel) can be scored in two locations to dividethe panel 50 into three rectangular plate 52, which correspond to thefour side walls of the collar 34. The length of the plates 52 of thefirst three-section pad 70 correspond to the width of the threecorresponding side walls of the box 20. The length of the plates 52 ofthe second three-section pad 72 correspond to the width of the top side,the length of the remaining side wall, and the width of the bottom side,respectively, of the box 20.

Together, the resulting two three-sectioned pads 70, 72 cover each ofthe six sides of the box 20 when inserted in the interior 22 of the box20.

It should be realized that other configurations are possible for the twothree-sectioned pads 70, 72. For example, the first three-sectioned padcould cover the bottom and two opposing sides of the box, and the secondthree-sectioned pad could cover the top and the other two opposing sidesof the box.

FIGS. 4A-4D illustrate yet another example of construction of the pads30 for the insulating shipping container 10. In the example of FIGS.4A-3D, rather than three pads, the thermally insulating pads 30 includesix pads 80, one for each of the six sides of the box 20.

FIG. 4A is a schematic exploded view of one of the pads. FIG. 4B is aschematic cross-sectional side view of one of the pads. FIG. 4C is aschematic perspective view of one of the pads. FIG. 4D is a schematicexploded perspective view showing how the two three-sectioned pads arepositioned relative to each other.

These pads 30 are constructed similarly to the pads discussed above forFIGS. 2E-2G, with each pad formed by sealing a solid compostable panelwithin a compostable water-proof film. Each pad (and each panel of thepad) has a length and width appropriate for the dimensions of theassociated side of the box 20, along the lines discussed above.

The example of FIGS. 4A-4D does not require scoring, and consequentlycan be easier to manufacture. However, the increased number of gapscould decrease the effectiveness of the thermal insulation.

FIGS. 5A-5H illustrate still another example of construction of the pads30 for the insulating shipping container 10. In the example of FIGS.5A-5H, rather than three pads, the thermally insulating pads 30 includea three-sectioned pads 90, and three individual pads 92.

FIG. 5A is a schematic exploded perspective view of the three-sectionedpad. FIGS. 5B and 5C are schematic cross-sectional side views of thethree-sectioned pad. FIG. 3C is a schematic perspective view of the twothree-sectioned pad. FIG. 5E is a schematic exploded view of one of theindividual pads. FIG. 5F is a schematic cross-sectional side view of oneof the individual pads. FIG. 5G is a schematic perspective view of oneof the individual pads. FIG. 6H is a schematic exploded perspective viewshowing how the two three-sectioned pads are positioned relative to eachother.

Referring to FIGS. 5A-5D, the three-sectioned pad 90 is constructedsimilarly to the three-sectioned pads discussed above for FIGS. 3A-3F,with the pad 90 formed by sealing a solid compostable panel within acompostable water-proof film. Referring to FIG. 5A, the three-sectionedpad 90 can be fabricated by forming a solid compostable panel 50 thathas a length L approximately equal to or slightly less than the heightof two side walls of the box 20 plus the length of the bottom of the box20, and a width W approximately equal or slightly less than the width ofone of the sides of the box 20.

Referring to FIGS. 5E-5G, the three individual pads 92 are constructedsimilarly to the top and bottom pads 32, 36 discussed above for FIGS.2E-2G, with the pads 92 formed by sealing a solid compostable panelwithin a compostable water-proof film. Each pad 92 (and each panel ofthe pad) has a length and width appropriate for the dimensions of theside of the box 20 which it will line, as generally discussed above.

Although FIGS. 5A-5C show the three-sectioned pad having a centersection that corresponds to the bottom of the box, this is notnecessary. The center section could correspond to one of the side wallsor the top of the box.

Even further configurations are possible for the pads 30, provided eachwall of the box is provided with an individual pad or a section of apad. For example, there could be three two-sectioned pads, or athree-sectioned pad, two-sectioned pad and an individual pad.

Moreover, there could be just a single pad 100 that fits inside the box20 and covers all six sides of the box 20. For example, FIG. 6, which isa schematic top view of a pad 100 in an unfolded configuration,illustrates a single six-sectioned pad. To fabricate this six-sectionedpad 100, the panel can be formed in a “cross-shape”, or another shapethat when folded will correspond to the sides of the rectangular prismof the box 20. The panel is sandwiched between two sheets, as discussedabove, and the edges are sealed along a path that runs close to theperimeter of the panel. Excess material of the sheets can be cut off.The panel can be scored with cuts 56 in five locations to divide thepanel into six sections. The scoring corresponds to the positionsnecessary for the panel to be folded such that each section correspondsto one of the sides of the box 20. Although the implementation shown inFIG. 6 is for a cubical box, this is not required.

The example of FIG. 6 may provide improved good thermal insulation dueto fewer gaps, and there can be a convenience for the customer to havejust a single pad for each box. On the other hand, this configurationmay have a cumbersome form factor.

The box 20 and pad or pads 30 that form the insulated shipping container10 can be provided as an unassembled kit, and be assembled by acustomer. For example, the box 20 and pads 30 could be shrink-wrapped orotherwise sealed together in packaging.

In any of the various examples discussed above, one or more apertures,e.g., about ⅛ to 5 inches across, can be formed through the film 60 onthe side of the pad 30 closer to the box 20, that is the side oppositethe opposite the cavity in which the item to be shipped is to bepositioned. These apertures are not present on the side facing thecavity in which the item to be shipped is to be positioned; the film 60on that side of the pad 30 is unbroken. The apertures can prevent pocketfrom acting like a balloon when the pad is inserted into the box—thefilm 60 can collapse against primary surfaces of the panels.

In some implementations, a pad includes only one panel in the pocketformed by the film. However, referring to FIGS. 7A and 7B,cross-sectional side views, in some implementations, the pad 30 includesmultiple panels 50. The panels 50 are stacked along their thicknessdirection, and not arranged side-by-side. This permits fabrication of athicker pad 30, thus increasing the thermal insulating capability. Forexample, this permits the total thickness of the pad to be about 1-4inches. In addition, avoiding gaps between that would occur withside-by-side panels can improve thermal insulation. In the example shownin FIG. 7A, there are three panels 50 a, 50 b and 50 c, but there couldbe just two panels or four or more panels.

For a multi-section panel, when the panels 50 are scored, the scoring 56can be performed by compressing the stack of panels along a line (ratherthan cutting the panels). As a result, in the scored region some of thepanels can be driven partially into the underlying panel.

Where the panels 50 are multi-section panels, sections at each end ofthe pad can be shorter than the section immediately underneath tocompensate for the stacking arrangement such that the ends of panels aresubstantially aligned. For example, as shown in FIG. 7A, section 52 b 1is shorter than the underlying section 52 a 1. In addition, the ends ofthe sections at the end of each pad can be cut at an angle. For example,as shown in FIG. 7A, the ends of sections 52 a 1 and 52 b 1 can be cutat an angle, e.g., a 45° angle. Thus, as shown in FIG. 7B, when themulti-section panels are folded inwardly, e.g., to form the U-shapedpad, the ends of the panels 50 align.

In the various implementations discussed above, the individual pads 30will rest on one another when inserted in the cavity of the box 20.However, the pads 30 are not fixed to each other, e.g., the pads are notsecured by adhesive or interlocking components to each other.

In some implementations, the solid compostable panels could be used, butwithout enclosing or coating the panels with a water-proof film. FIG. 8is an exploded perspective view of an example of another implementationof an insulated shipping container 10. The shipping container 10includes a recyclable box 20 and multiple thermally insulatingcompostable panels 50 that fit inside the interior cavity 22 of the box20. The panels 50 are shaped such that when positioned in the box 20they provide an interior space to receive the item and optionally acoolant, e.g., ice, dry ice or a gel pack.

Optionally, a recyclable interior box 90, e.g., a cardboard box, can fitinto a space defined by the interior of the panels 50. In this case, theinterior cavity of the interior box 90 provides the space to receive theitem and optionally a coolant. The interior box 90 can provideadditional thermal insulation, and can protect the panels from water,e.g., condensation caused by coolant. However, as noted above, the itemand coolant could be placed into the interior space, without using theinterior box.

Each panel 50 can be fabricated as discussed above, e.g., formedprimarily of extruded milled sorghum, so as to be compostable. However,the panels are not coated with, enclosed in, or otherwise protected by awater-proof film. Rather, the panels 50 are simply inserted into thecavity 22 in the box. One or more of the panels 50 can be amulti-section panel, which is scored as discussed in the variousimplementations discussed above, and then folded at right angle toprovide multiple rectangular plates.

In the implementation shown in FIG. 1, the thermally insulating panels50 include a bottom panel 82, a collar 84, and a top pad 86.

The bottom panel 82 has a length and width that match the bottom of thebox 20, or are slightly smaller, e.g., by about an ⅛ inch tolerance, sothat bottom panel 82 fits snugly at the bottom of the cavity 22 on thebottom of the box 20.

The collar 84 includes a single panel that is folded into fourrectangular plates. The four rectangular plates provide four wallmembers 40, which are equivalent to the wall members discussed withrespect to FIG. 1, but without the water-proof film. Each wall member 40has a height (in the vertical direction) about equal to the height ofthe box 20, less the combined thickness of the top panel 82 and bottompanel 86. Each wall member 40 has a width (in the lateral direction)that matches the adjacent side wall 24 of the box 20, or is slightlysmaller, e.g., e.g., by about an ⅛ inch tolerance. Thus, the collar 84fits snugly into cavity 22 on top of the bottom panel 82, with each wallmember 40 adjacent, e.g., in contact with, one of the side walls 24.

The top panel 86 has a length and width that match the top of the box20, or are slightly smaller, e.g., e.g., by about an ⅛ inch tolerance,so that the perimeter of the top panel 86 can sit on the wall members 40of the collar 84 and the top panel 86 itself fits snugly at the top ofthe cavity 22.

Although FIG. 8 illustrates a configuration for the panels 50 that issimilar to the configuration of pads 30 in FIGS. 1 and 2A-2G, otherconfigurations for the panels, e.g., equivalent to those shown in FIGS.3A-3I, FIGS. 4A-4D, FIGS. 5A-5H, or 6, are possible. Similarly, multiplepanels 50 can be stacked, e.g., as illustrated in FIGS. 7A-7B, but againwithout the water-proof film.

Although milled sorghum is discussed above, it may be possible to formthe panel out of a grain starch, such as corn starch or wheat starch.However, sorghum is generally superior in that it can provide superiorthermal insulation than corn starch. In addition, the particulates ofmilled sorghum may be more amenable to extrusion.

Referring to FIG. 9, although in some implementations multiple panelscan be stacked without being joined, it is also possible for multiplepanels 50 to be stacked and laminated together. This can increase thetotal thickness of the resulting panel, e.g., to 1 to 3 inches thick.The stacked panels can be joined by a thin layer of compostable adhesive100.

It should be understood that although various terms such as “top”,“bottom”, “vertical” and “lateral” are used, these terms indicaterelative positioning of components under the assumption that an openingto the box 20 is at the top, and don't necessarily indicate anorientation relative to gravity; in use, or even during assembly, thecontainer 10 could be on its side or upside down relative to gravity.The term “slightly” indicates no more than about 5%, e.g., no more than2%.

A number of embodiments have been described. Nevertheless, it will beunderstood that various modifications may be made without departing fromthe spirit and scope of the invention. Accordingly, other embodimentsare within the scope of the following claims.

What is claimed is:
 1. A shipping container to hold an item, comprising:an exterior box having a floor and a plurality of side walls to define acavity therein and an opening to the cavity at the top of the box; acover to close off the top of the box; and a plurality of thermallyinsulating pads positioned in the cavity, the plurality of thermallyinsulating pads positioned such that each of the floor, plurality ofside walls and cover are adjacent to and covered by a pad from theplurality of thermally insulating pads, the plurality of thermallyinsulating pads shaped to provide an interior space to receive the item,wherein each pad of the plurality of thermally insulating pads includesa solid compostable panel formed primarily of a starch that holdstogether as a single unit, the panel providing a rectangular platedimensioned to substantially span whichever of the floor, plurality ofside walls or cover that the rectangular plate is adjacent, and acompostable water-proof film forming a pocket enclosing the panelwithout being bonded to the panel; wherein at least one of the pluralityof thermally insulating pads includes a plurality of rectangular panelsections, wherein the pad is folded at a right angle along a boundarybetween the panel sections and each panel section is dimensioned tosubstantially span whichever of the floor, plurality of side walls orcover that the plurality of plates is adjacent, and wherein the filmprovides both an interior surface of the pad and an exterior surface ofthe pad where the pad is folded with all of the panel sections enclosedin the same pocket.
 2. A thermal insulation assembly for placement in ashipping container to hold an item, comprising: a plurality of thermallyinsulating pads shaped to be positioned in a cavity of a rectangularprism shipping container such that each of a floor, plurality of sidewalls and cover of the container are adjacent to and covered by a padfrom the plurality of thermally insulating pads and an interior space isprovided to receive the item, wherein each pad of the plurality ofthermally insulating pads includes a solid compostable panel formedprimarily of grain starch that holds together as a single unit, thepanel providing a rectangular plate dimensioned to substantially spanwhichever of the floor, plurality of side walls or cover that therectangular plate is adjacent, and a compostable water-proof filmforming a pocket enclosing the panel without being bonded to the panel;wherein at least one of the plurality of thermally insulating pads is amulti-section pad including a plurality of rectangular panel sectionsenclosed by the film, wherein the multi-section pad is configured to befoldable at a right angle along a boundary between the panel sectionsand each panel section is dimensioned to substantially span whichever ofthe floor, plurality of side walls or cover that the plurality ofrectangular panel sections is adjacent, and wherein the film providesboth an interior surface of the multi-section pad and an exteriorsurface of the multi-section pad where the pad is folded with all of thepanel sections enclosed in the same pocket.
 3. The assembly of claim 2,wherein an interior of the pocket is evacuated of air.
 4. The assemblyof claim 2, wherein the panel is loose within the pocket.
 5. Theassembly of claim 2, wherein the at least one of the plurality ofthermally insulating pads comprises a score across its width in at leastone location on an interior surface of the panel, the score extendingpartially but not entirely through the thickness of the multi-sectionpad to divide the panel into the plurality of rectangular panelsections.
 6. The assembly of claim 5, wherein the score comprises acompressed portion of the multi-section body.
 7. The assembly of claim5, wherein the score comprises a cut out portion of the multi-sectionbody.
 8. The assembly of claim 2, wherein the starch comprises cornstarch, wheat starch or milled sorghum.
 9. The assembly of claim 2,wherein the panel of each pad has a uniform homogenous composition. 10.The assembly of claim 2, wherein the panel of each pad is a unitarybody.
 11. A thermal insulation article for placement in a shippingcontainer to hold an item, comprising: a multi-section thermallyinsulating pad shaped to be positioned in a cavity of a rectangularprism shipping container to be adjacent to and cover from two to five ofout of a floor, four side walls and cover of the container while leavingan interior space to receive the item, wherein the thermally insulatingpad includes a plurality of solid compostable panel sections formedprimarily of grain starch, each panel section holding together as asingle unit, each panel section providing a rectangular platedimensioned to substantially span whichever of the floor, plurality ofside walls or cover that the rectangular plate is adjacent, and acompostable water-proof film forming a pocket enclosing the plurality ofpanel sections without being bonded to the panel sections; wherein themulti-section thermally insulating pad is configured to be foldable at aright angle along a boundary between the panel sections, and wherein thefilm provides both an interior surface of the multi-section thermallyinsulating pad and an exterior surface of the multi-section thermallyinsulating pad where the multi-section thermally insulating pad isfolded with all of the panel sections enclosed in the same pocket. 12.The article of claim 11, wherein an interior of the pocket is evacuatedof air.
 13. The article of claim 11, wherein the plurality of solidcompostable panel sections are slidable within the pocket.
 14. Thearticle of claim 11, wherein the multi-section thermally insulating padcomprises a panel having a score across its width in at least onelocation on an interior surface of the panel, the score extendingpartially but not entirely through the thickness of the panel to dividethe panel into the plurality of panel sections.
 15. The article of claim11, wherein the plurality of solid compostable panel sections each havea thickness between of about ¼ and 1 inch.
 16. The article of claim 11,wherein the plurality of solid compostable panel sections each have adensity of about 0.6 to 3.5 g/cm³.
 17. The article of claim 11, whereinsurfaces of each of the plurality of solid compostable panel sectionsare basically flat.
 18. The article of claim 11, wherein one or moresurfaces of one or more of the plurality of solid compostable panelsections are corrugated.
 19. The article of claim 11, wherein the starchcomprises corn starch, wheat starch or milled sorghum.
 20. The articleof claim 11, wherein the multi-section thermally insulating pad includesa plurality of stacked panels.